Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Fender · Post by **Fender** » Thu Oct 08, 2020 9:10 am

I asked Charlie how he was welding the stays, and he sent these photos. He pre-positions the ring for filler metal when making the first TIG pass.

Pipescs · Post by **Pipescs** » Thu Oct 08, 2020 10:04 pm

Evening all,

Just received a very nice email from Marty Knox explaining this is not the preferred method of welding in the stay bolts.

The stay is supposed to be welded to the sheet but you want to leave as much of the rod as you can intact. You are supposed to see the rod in the center of the weld. There is no way I would put a ring of TIG filler in the weld like that. You can't see that it is all melting.

Marty was very nice in offering instruction without stomping my toes.

As a beginner at this it is always appreciated when friendly advice is offered.

All should remember I was brought into this hobby by Larry Kombrink who more than once commented "Pipes, you can't be that stupid".

So needless to say I am pretty thick skinned and open to correction and guidance.

Charlie

Pipescs · Post by **Pipescs** » Mon Nov 16, 2020 3:11 pm

Back again,

After working with Marty and Pontiac Guy I am now corrected on the welding of stay-bolts. Not saying I am an good at this, just getting better.

All the stays except the three on the throat sheet are completed.

These three will be finished after the boiler is stood on end to weld in the front tube sheet.

Today I made up the fixture to hold the front tube sheet in place where I can tack it into place.

I drove over to Pulaski TN today and ordered the Schedule K copper for the Tubes.

Marty_Knox · Post by **Marty_Knox** » Mon Nov 16, 2020 4:07 pm

Charlie, did you ream the holes in the front tube sheet oversize? It's a lot easier to slide the tube in if it's about .010" larger than the nominal diameter of the tube. For instance, when I use 5/8" OD tubes I ream the front tube sheet .635". I still ream the rear tube sheet .625".

Pipescs · Post by **Pipescs** » Mon Nov 16, 2020 5:38 pm

Sure did, The tubes are 3/4 id Schedule K Copper. Reamed the Rear tube sheet to .75 and then re-reamed it after welding. The front sheet is oversized to .009 over and the will be re-reamed after welding.

Pontiacguy gave me three short lengths of copper and they are a smooth slide fit in the front sheet and will be a press fit in the firebox end.

Pontiacguy1 · Post by **Pontiacguy1** » Tue Nov 17, 2020 8:49 am

He means .875". not 3/4"

Pipescs · Post by **Pipescs** » Thu Nov 19, 2020 6:47 pm

Picked up the Copper Pipe for the Tubes tonight. I am fast running out of excuses to not finish this part of the project.

Berkman · Post by **Berkman** » Thu Nov 19, 2020 9:48 pm

you'll have it under steam before long!

Pipescs · Post by **Pipescs** » Mon Dec 14, 2020 9:48 am

So we are at the point of taking it up to Pontiacguys shop to roll in the tubes and a Hydro. All the plugs are in, steam dome installed and the welding is complete. Well, that is until we find the leaks.

In mentioning taking it to Tennessee to roll in the tubes I will make note that you cannot build a boiler without one of these.

Post by **Harold_V** » Mon Dec 14, 2020 4:21 pm

Charlie,
If those welds are as good as they look, I'm really impressed. Beautiful job you've done.

H

Pipescs · Post by **Pipescs** » Sun Dec 20, 2020 6:38 pm

Thanks Harold,

Yesterday was busy, Pontiacguy was kind enough to drive down from Tennessee to bring me a tubing roller and the equipment to pressure test the boiler. Most importantly he brought the expertise on how to roll in the tubes. He stayed with me for the first four and then left it all with me to continue. All the tubes were rolled in by lunch and after my noon day nap I sealed it up and applied water from the hose.

With just the 70 PSI from my local water tower down the road, I located 8 leaks. I am happy to say there were no leaks in the tubes. All except one on the dry stay going thru the front tube sheet were on Stay Bolts that I had welded in with 6010/7018 rods. All the ones I did with TIG did not leak. Nor did any of the cleanout bushings. Definitely will continue to pursue the use of TIG welding on the other boiler project.

After grinding and repairing all the leaks I took it to 400 PSI only to find another weeping leak on a stay bolt. It is not even a stream. Just a wetness around the stay. Hopefully I will get to this one on Tuesday.

Once again, Thanks to everyone who has given so much help on this project.

LVRR2095 · Post by **LVRR2095** » Mon Dec 21, 2020 6:08 am

Pipescs wrote: ↑Sun Dec 20, 2020 6:38 pm Thanks Harold,

After grinding and repairing all the leaks I took it to 400 PSI only to find another weeping leak on a stay bolt. It is not even a stream. Just a wetness around the stay. Hopefully I will get to this one on Tuesday.

Once again, Thanks to everyone who has given so much help on this project.

DSC_5862.jpg

Why did you take it to 400psi???? Are you planning an operating pressure of 200 psi?

Keith

The Home Machinist!

Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4

Re: Converting a Baldwin 2-4-2 LYN to a Baldwin 2-4-4